Low-cost tough decorative printable film products having holographic-type images

ABSTRACT

Tough decorative printable film products having holographic-type images are provided that are low in cost. These film products include a relatively high temperature film that is made by continuous extrusion of the film resin onto a master film having pre-etched holographic-type imaging in order to provide a high-temperature primary film with conforming holographic imaging. This primary film provides a tough holographic-type image that is readily secured to any number of products to impart a holographic character to them. For example, this primary film is suitable for use on the surface of recreational sportsboards. When desired, sublimation printing can be used to impart indicia, text, images and colors, alone or in combination, to the primary film.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of co-pending U.S. application Ser. No.11/399,847, filed Apr. 6, 2006, which is a provisional of U.S. PatentApplication Ser. No. 60/669,221, filed Apr. 7, 2005, both herebyincorporated by reference hereinto.

FIELD OF THE INVENTION

The present invention is related to decorative film products that haveholographic-type images and that are printable. More particularly, theinvention relates to products of this type which provide a low-costapproach for providing such film products that are suitable for avariety of uses, including for uses that exert considerable wear andtear on the film, so as to be suitable for providing decorativeenhancement to products including so-called recreational sportsboards.

BACKGROUND OF THE INVENTION

Traditional holographic films typically are made by a proceduresummarized as follows. A substrate (such as an acrylic coated orientedpolyester film) is coated with an embossable coating. This film is thenpassed across an etched roller under heat and pressure to emboss thecoating. Typical embossment depths are a few angstroms to about 2 mils.A clear high refractive index material (typically indium tin oxide orzinc sulfide) or a metal (often aluminum) is applied to the embossedside to preserve the image integrity. Such holographic decorative filmsare commercially available under the trademark SPECTRATEK®, ofSpectratek Technologies, Inc., as are other products from other sources.When desired, these can be available in the art without the highrefractive index (HRI) material or aluminum having been applied to theembossed surface.

It will be appreciated in the art that these types of traditionalholographic films essentially are films that have been embossed. Oftenin the art, a holographic embossed film includes at least one layer thatreflects light at an angle different from other panels or portions ofthe surface having the embossment. These films can be said to havediffractive optical elements, jagged etch cuts, image-imparting prismaletching, micro-angled cuts, or prismal or holographic style effects.Such elements often give the embossed film refractive characteristicsthat typically vary with the angle and wave length of the light emittedonto the embossed surface. The terms holographic and embossed, when usedherein, signify a surface that has embossed members or facets. Whilethese embossed films or surfaces can exhibit the diffractive opticalelements that often are labeled as holographic, a strict definition ofholographic is not intended. Instead, such term refers to surfaces orfilms that have differing depth characteristics, that is they areembossed, whether or not the reflective angles are such as to fallwithin a strict definition of holographic.

Over the years, embossment approaches have been used to provide orenhance decorative and/or functional polymer film surfaces. These caninclude embossments that have strict holographic properties which oftenare considered desirable due to their unique and eye appealing andinterest-generating aspects. Often, it is essential that such productsexhibit an eye-catching character that can be imparted by highrefractive index (HRI) materials by adding the materials or metalsdiscussed above and that typically are applied as a clear or transparentlayer onto the embossed areas of the film. While this is oftensuccessful in preserving image quality and surface integrity, it hascome to be appreciated that holograms made in the traditional waydescribed hereinabove are susceptible to weaknesses that can bemanifested when such embossed films are to be included on products thatare expected to be used under rugged conditions. Typical holographic orembossed films are not durable when subjected to harsh environmentalconditions, particularly including repeated and forceful physicalcontact with rigid items, which often involves kinetic energy transferupon contact between the holographic surface and such an item. These cantake the form of impacts from rigid objects hurled onto the surface orobjects that, due to the nature of the holographically decorated productconstantly engage and impart forces into the surface.

Weaknesses in these instances can include the following. HRI coatingsand adhesive layers used in such traditional holographic films canexhibit low thermal stability, making them vulnerable to higherprocessing temperatures and to environmental degradation, such as wouldbe encountered in outdoor use. In addition, material breaks occur atinterfaces, particularly when overlayer barriers are used when theproduct is intended for rugged applications. Metallized top layers, forexample, which can also impart added reflectance and a metallic look,can experience breaks due to relatively weak bonds at layer interfaces.Particularly problematic in this regard are material breaks atinterfaces between metallized layers and layers of other materials orfilms.

Accordingly, in the art, it is generally understood that decorativeembossings and holograms cannot be used on products that are intendedfor rugged end use. This is because the holograms will split apart andcompromise the construction of the product. The art would generallybelieve that standard hologram approaches would split if the materialwere exposed to situations under which substantial stress and/or impactis imparted repeatedly. Accordingly, there is a need for an approachthat addresses these concerns and provides a durable approach forapplying decorative embossed surfaces onto products that will avoidthese types of splitting and separation concerns.

Often, it is further desired that decorative surfaces that haveholographic or embossed characteristics also have images applied to thesurface. Typically, images would be applied by printing, inking ordyeing techniques. One problem that is recognized with holographic orembossed surfaces is that many printing, inking and dyeing techniquesobscure the embossed or holographic effect. It is believed that this canbe caused by the inking media filling several or all of the embossmentdepressions. This can be referred to as “wetting out” or “clearing” theholographic imagery. It will be appreciated that filling or coating someor all of the depressions changes the reflectance of the hologram orembossment. Conventional printing techniques, such as those usingconventional inks include offset, flexographic and lithographictechnologies, experience this “wetting out.”

While it has been generally appreciated that dye sublimation imprintingis a useful means of direct image transfer, prior publications such asFlaherty, U.S. Patent Publication Number 2004/0143914 do not teach howto use dye sublimation technology in a manner that is suitable forlow-cost rugged use. For example, the Flaherty publication describes alaminate having a frangible hologram embedded therein, while providing asurface that is receptive to dye sublimation direct image transfer.

Benton et al., U.S. Pat. No. 6,632,507 discusses holographicallyenhanced decorative laminates, teaching heat and pressure embossinglamination. This describes a laminate sheet assembly having apolypropylene-based release sheet that, upon the application of heat andpressure, transfers a holographic image onto an overlay layer of thelaminate for application to a rigid substrate such as plywood, particleboard, chip board and medium density fiberboard. By this approach, thepolypropylene-based sheet containing the holographic image functions asa release sheet for conventional decorative laminate lay-ups having theoverlay layer, a pattern layer and a core layer which is composed of oneor more layers of phenolic resin impregnated craft paper. The overlaylayer is said to include aluminum oxide for wear resistance. While thispatent is intended for application to rigid substrates and for ruggeduse such as countertops, flooring panels and wall panels, this isaccomplished in a somewhat traditional manner of using laminate sheetassembly onto which a holographic image is impressed by heat andpressure into an overlay layer to which a wear coating is applied afterthe holographic image is formed thereon.

Another approach which incorporates transfer of physical embossment of aholographic image is illustrated by Stepanek, U.S. Pat. No. 5,900,095.This encompasses, for example, a transfer of a holographic image from apolymeric support to a tissue paper substrate. This patent and all otherpatents, references and publications identified herein are incorporatedhereinto by reference.

Prior approaches such as these require somewhat complicated means forimparting embossed or holographic images. While some of this artdiscusses relatively rugged uses, this can increase complexity accordingto the solutions given by this prior art. They are also not described asbeing particularly well suited for combining holographic technology withprinting, inking or dying in order to impart indicia, wording, images orother decorative or informative elements, typically when combined withmultiple color displays. Accordingly, the art does not provide anapproach by which holographic features can be employed in a low-costmanner that is advantageously straight forward and is well-suited torugged uses including for recreational sportsboards, as well as otheruses where simplicity and durability are assets. Further needs areappreciated where one wishes to combine a holographic or embossedfeature with a printing, inking or dying feature, particularly one inwhich the holographic type feature and the additional decorativefeatures are simultaneously visible on the product.

SUMMARY OF THE INVENTION

The present invention employs holographic or embossed features from theembossed film of holographic sheeting systems that are not particularlysuitable for rugged uses. This embossed film is totally separated fromthe rest of the sheeting system to provide a master having the desiredembossed pattern. Molten polymer is extruded onto the master embossedfilm, thereby filling in the embossed depressions. Upon cooling, theextruded polymer forms a reverse-imaged film, which film is of a polymerthat is hard and durable and is a sublimation dye-receptive polymer.This is the primary film that is viable on its own and can be marketedto manufacturers of products including those where durability in theface of rugged use is essential.

In a preferred embodiment, this primary film has sublimable dye,typically in a combination of images, text or other indicia, often inmultiple colors, applied to the primary film chemically absorbed intothe polymer of the primary film, thereby combining the holographic-likefeature and the dye feature to provide a product having dye images andvaried holographic attributes visible simultaneously.

In a further embodiment, a backing is applied to the primary film on theside opposite to the embossed imagery, typically after sublimation dyetreatment. This backing is suitable for applying the primary film to acomponent that is to be decorated with holographic properties, such as arecreational sportsboard.

A general aspect or object of the present invention is to provide aprimary film having embossed holographic or holographic-like patternsand made of hard and durable polymer material that is sublimationdye-receptive.

Another aspect or object of this invention is to provide a producthaving a durable hologram-containing polymer sheet that is sublimationdye printed and that exhibits both holographic and printed propertiessimultaneously in the same locations, giving the appearance of aholographic image contained within a printed area.

Another aspect or object of the present invention is to providerecreational sportsboards and other products having similar propertiesthat are hard and durable and that exhibit hard and durable holographicand printed characteristics simultaneously on the visible surface of theproduct.

Another aspect or object of this invention is directed to athermoplastic film having an embossed holographic image on a surfacethereof, which surface is adapted to receive gaseous phase dye diffusionprinting applied directly thereon.

Another aspect or object of this invention is a thermoplastic filmhaving a holographic image which can be incorporated into productssubjected to high impact use.

Another aspect or object of this invention is a process for embossing aholographic image on durable thermoplastic materials using a selectedlayer from commercially available holographic decorative film sheetingas the master.

Yet another aspect or object of this invention is an embossed profilesheet for packaging which is not removable, does not result in curlingof the packaging and receives gaseous phase dry diffusion printing thatdoes not obscure the holographic-type image.

Other aspects, objects and advantages of the present invention will beunderstood from the following description according to the preferredembodiments of the present invention, specifically including stated andunstated combinations of the various features which are describedherein, relevant information concerning which is shown in theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration in cross-section depicting a portionof a prior art holographic film product having an embossed prismaticholographic image thereon;

FIG. 2 is a schematic illustration in cross-section of the base film ofthe product of FIG. 1 which has the embossed image;

FIG. 3 is a schematic illustration in cross-section of the film of FIG.2 shown being used as a master that has been extrusion coated with ahigh-temperature sublimation dye receptive polymer material;

FIG. 4 is a schematic illustration in cross-section of the extrudedpolymer shown in FIG. 3 after removal of the base film of FIG. 2 inorder to provide a tough decorative primary film having an inverseholographic image embossed on a surface of this decorative primary film;

FIG. 5 is a schematic, cross-sectional illustration depicting a patternof heated gaseous-phase sublimation ink applied to portions of theprismatic surfaces of the inverse holographic image of the FIG. 4decorative primary film to form a printed image sublimated into theholographic image and below the surface of the primary film;

FIG. 5 a is a schematic, cross-sectional illustration depicting apattern of conventionally printed ink applied to portions of theprismatic surfaces of the inverse holographic image of the FIG. 4decorative primary film to form a printed image which can cover and hidethe embossed holographic effect of the primary film in said printedarea;

FIG. 6 is a top plan view of the sublimation inked product of FIG. 5showing the holographic image visible in both inked and uninked areas;and

FIG. 7 is a schematic, cross-sectional illustration of one of theseholographic image embossed sublimation printed decorative primary filmslaminated to a base layer of porous non-woven fleece by an intermediatelayer of interlocked non-woven fleece and thermoplastic material, suchbeing suitable for imparting a decorative surface to the face of asportsboard.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely exemplary of the invention, which may be embodied in variousforms. Therefore, specific details disclosed herein are not to beinterpreted as limiting, but merely as a basis for the claims and as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention in virtually any appropriate manner.

FIG. 1 illustrates a typical roll of holographic decorative filmsheeting, generally designated at 11. Shown is a high refractive index(HRI) coating 12 that fills jagged etch cuts 13 that are embossed into abase film 14 of the sheeting 11. A metallized top layer 15 is shown overthe HRI coating. This top layer typically is metallized and contributesreflectance and a metallic look to the sheeting. The HRI coatingprotects the etched image and allows light transmission in order tofacilitate any desired holographic effect. Illustrated sheeting 11 istypical of prior art holographic-type sheeting systems that areavailable in the art.

The present invention employs base film sheeting 14 from products suchas sheeting system 11. Alternatively, it can be possible to produce orobtain such an embossed or holographic base film 14. Such base films 14(FIG. 2) are made of embossable material to which a hologram pattern isapplied in order to form the jagged etch cuts 13 or other styles ofembossment. Not only is the base film sheeting embossable, but it alsomust be suitable for extrusion of a polymer thereover to form theprimary film discussed herein. The base film sheeting may be acoextrusion. The base film sheeting must be made of a polymer and/orcoextrusion that is heat resistant to melting or distorting at thetemperature of the extrudate when it touches the base film, and its melttemperature should exceed the temperature of the polymer from theextruder at the time the extruded polymer contacts the base filmsheeting.

Typically, the embossable material out of which the base film 14 is madeincludes an oriented film such as a biaxially oriented film stretched intwo dimensions. Preferred is oriented PET, or oPET. Other materials forthis can include those of commercial holographic or embossed sheetingsuch as SPECTRATEK® sheeting or other known sheetings that have thecharacteristics required herein. Typically, these polymers will have aminimum melting point or melt temperature of at least about 150° C.,preferably at least about 160° C. (320° F.), more preferably at leastabout 175° C. (350° F.). Generally, it is important that the Tm valueand Tg value or values be high enough that the sheeting that is used asthe base film 14 be able to maintain the integrity of its embossed orholographic character.

This base film 14 can be a coextrusion of the aforementioned materialsuch as oPET and an overlayer that has exceptional initial embossingreceiving characteristics. Such a layer can be amorphous. A suitablenon-crystalline polymer is a relatively soft polyester in thepolyethylene terephthalate (PET family). Amorphous PET film moleculesare not aligned or ordered within the material. Materials such as theseare well-suited to accept and retain embossing patterns, includingjagged edge cuts and prismal etching with micro-angled cuts typical ofholographic embossments, while also exhibiting good laminationproperties. Amorphous PET itself has a moderate-to-low temperaturestability range of about 60° C. to about 70° C. (about 140° F. to about158° F.).

This invention takes the embossed sheeting roll of holographicdecorative base film 14 and uses that embossed film as a master toemboss hot molten polymer through an extrusion process to form acombination of films 14 and 16, generally designated as 17 in FIG. 3.Once cooled, the holographic decorative base film sheeting 14 is removedfrom the combination 17 to provide the resulting extruded polymerprimary film 16 (FIG. 4). The separated base film sheeting master 14usually can be reused to further lower cost.

If desired, the film 14 could be left on the primary film 16. In thatcase the combination that is generally designated 17 in FIG. 3 can beused as a “peel and reveal” product. This effect is due primarily tothere being no net angle of holographic or embossed reflection while thefilms 14 and 16 are ultimately conformed in mirror image to one another.With such a product 17, the holographic or embossed image is notvisible. Thus, until the base film 14 and the primary film 16 areseparated or “peeled” from each other, the holographic or embossed imageis not visible under unaided viewing. The images are revealed uponseparation. This provides a useful way of storing or shipping theprimary film 16 in order to provide extra protection therefor untilafter same is ready for use.

Alternatively, the primary film 16 can be provided in this “peel andreveal” form and used in this form while being further processed intofinal products. At an appropriate stage, the base film 14 is removed toreveal the holographic image and proceed with further processing,including but not limited to processing into recreational sportsboardsand other products as discussed elsewhere herein.

In keeping with many preferred embodiments of the invention, theextruded polymer primary film 16 having the holographic or otherembossed image thereon, is made of a polymer suitable for the objectivesof this film. More specifically, polymer out of which the primary film16 is made has good toughness and a relatively high melting point and/orglass transition temperature. The extruded polymer primary film 16exhibits heat resistance that is high enough to avoid melting ordistorting of the embossed facets being formed or already formedtherein, including when at the temperature of the extrudate of thispolymer when it touches the base film 14 to form the product 17 of FIG.3. Generally, this is to be achievable when using base film 14 in whichthe highest melting point polymer has a melting point (Tm) of at leastabout 175° C. (about 350° F.) as measured by ASTM Test Method D-3418. Aninstrument such as a DSC7 differential scanning calorimeter commonly isused.

The extrudate that forms the primary film 16 will be of a polymer havinga similar Tm of at least about 175° C. (about 350° F.). Preferably theTm of primary film 16 is at least about 200° C. (about 418° F.), and ashigh as at least about 220° C. (about 430° F.). In particularsituations, the Tm could be as low as about 160° C. (320° F.). Forexample, it may be possible for some dye sublimation to occur at atemperature this low. This polymer also is hard and durable enough forsportsboard and other rugged uses, as may be desired, without additionalcoatings. The polymer also is suitable for high-speed continuous rolledfilm manufacture.

Thermoplastic materials that are suitable as the coating or extrudedpolymer primary film 16 for one or more of the embodiments include thefollowing: polybutylene terephalate (PBT), high impact polystyrene(HIPS), polystyrene, high melting point polyolefins, polypropylene,polyethylene, polyethylene terephalate-glycol (PET-G), polytrimethyleneterephthalate, polyethyl vinylacetate copolymer (EVA), polyethyl ethylacrylate copolymer (EEA), polyethyl methyl acrylate (EMA). Otherthermoplastic materials that are believed to be suitable as the coatingor extruded polymer primary film 16 include the following: polycarbonate(PC), polyurethane (PU), polyvinyl chloride (PVC), acrylic resins,nylons, and acrylonitrile butadiene styrene (ABS) resin. Suitablethermoset materials, or the softer and/or lower softening and/or higherTm thermoplastics, typically would need to be cross-linked after itsseparation from the holographic decorative film or base film or master14.

Also, the polymers of the extruded film 16 should not be classified ashaving strong adhesive characteristics. Such polymers provide for mucheasier release properties, for example from the base film sheeting 14.Higher Tm and higher softening polymers tend to exhibit the desirablelower adhesive properties.

Further details concerning thermoplastic polymers that are suitable forthe primary film 16 include the following. An example of a PBT polymerthat is suitable is ULTRADUR 4500 (available from BASF). This has amelting temperature (Tm) range of between 218 and 231° C., and averagemelt temperature of about 223° C., an average glass transitiontemperature (Tg) of about 66° C. and a heat deflection at 66 PSI ofabout 164° C. A particular polyethylene terephalate type of polymer(oPET) has a melt temperature (Tm) range of about 180 to 270° C.,usually between about 246 and 265° C. A typical polyamide or “nylon” hasa Tm range of about 190 to 265° C., typically between about 210 and 230°C. A polyurethane (X 1014, available from Noveon) has a Tm range of fromabout 180 to 230° C., a Vicat softening point (measured according toASTM Test Method D-1525) of 155° C., and a Tg range of from about 120°to 160° C. (Perken Elmer). A suitable modified polyester (Crystar4-1621) has a Tm of about 220° C. and a Tg of about 70° C. The Tg valuesare as determined by ASTM Test Method E-1356. A DSC7 also is useful forthis measurement.

Furthermore, in a preferred embodiment, the polymer of the extrudedprimary film has excellent hardness and durability properties andinherently accepts dye sublimation printing. Such polymers provide agood dye receiver substrate and are good sublimation dye-receptivepolymers. Such polymers are chemically receptive and reactive withsublimation dyes. According to this aspect of the invention, sublimationdyes attach especially well to polyester-based polymers, binding the dyewhile in its gaseous form.

High temperature resins referenced specifically for dye sublimationprinting must be able to withstand temperatures associated withsublimation printing, typically about 171-204° C. (about 340-400° F.) orgreater without a substantial material distortion resulting. Thus, theresin must remain a solid and not become tacky or flow during theprinting process. This technique is not intended to be limited tothermoplastic materials. Appropriate thermoset resins may also be usedin sublimation printing, and are often adequately thermally resistant.Thermoplastic polymers especially suitable for dye sublimation printinginclude a polyester, polybutylene terephthalate, polytrimethyleneterephalate, acrylics, nylons, polyurethanes, and combinations thereof

With further reference to the use of sublimation dyes on these types ofpolymers, a surface penetration phenomenon is observed. This phenomenonallows for graphics, text, indicia and/or colors to be placed on thetarget material surface without the printing profile interfering withthe holographic-type feature. This aspect allows for complete retentionof the holographic-type surface characteristics that are embossed intothe base film 14 and transferred to the primary film 16 by the extrusionprocess while adding the decorative features of sublimation dyeprinting. This forms the decorated primary film 16 a having dye 18 (FIG.5).

Although not wishing to be bound by any theory, a dye sublimationmechanism that is believed to be followed with this aspect of theinvention can be summarized in the following manner with respect topolyesters. A typical polyester molecule breaks open at about 163° C.(325° F.). This effects chemical bonding of the polyester to the heatedsublimation dye. After cooling, the polyester molecules close, therebypermanently binding the dye in place and avoiding dye migration. Duringdye diffusion printing, the dye thus sublimates below the surface of thesubstrate or film and does not destroy the embossed pattern, such as byfilling in any portion of a holographic pattern. The hologram-likepattern remains visible in both printed and unprinted areas. This can beconsidered to be a form of “chemical coloring.”

With further reference to printed embodiments, the extruded polymertough and relatively high melting primary film 16 a bearing aholographic image can be printed by dye diffusion transfer directly onthe holographic image without an interim treatment to increaserefraction. The embossed surface on the extruded polymer has aholographic image that is visible in both printed and unprinted areas ofthe polymer surface after printing by the dye diffusion transfer.

FIG. 5 a illustrates an approach where the primary film 16 isconventionally printed. This includes a conventional ink filling injagged etch cuts 13, as indicated at 25.

A typical method for manufacturing products according to the inventionon an industrial scale includes the following. A roll of holographicbase film 14 with a resistance to deformation to heat greater than about350° F. (175° C.) can be provided. This roll is embossed with aholographic-like image but does not have a coating of a high refractiveindex (HRI) coating or metallized layer. The roll of holographic basefilm is coated with a polymer, typically a thermoplastic material,through an extrusion process on the embossed side. Suitable rolls ofholographic image receiving base films can be purchased from holographicfilm manufacturers and/or suppliers such as Crown Roll Leaf, Inc.,Spectratek Technologies, Inc., or Holosource.

The holographic base film is mounted on the primary, secondary,auxiliary, or foil unwind locations of a commercial line. Usually, thefilm is not treated by traditional means that would typically create agreater bond between its base substrate film 14 and the extrudate formedinto the primary film 16. Such traditional treatment includes but is notlimited to primers, corona treatment, flame treatment, or ozoneexposure. However, if premature release occurs between the basesubstrate film 14 and the extruded polymer, some level of corona orflame treatment may be desirable and enough to allow the holographicfilm to continue through the operation without prematurely releasingfrom the extruded polymer.

The holographic base film master should have enough heat resistance toavoid distortion or melting at the temperature to which the extrudatehas cooled when it touches the film. As a rule of thumb, the extrudatewill cool from about 50° to about 100° F. through the air gap. As aresult, the temperature at the lamination station will be the melttemperature minus about 50 F. degrees (as a maximum). While the chillrollers will immediately pull the heat from the molten polymer, it isimportant to avoid too high a temperature at the film extrudateinterface to avoid distorting or destroying the embossed pattern orbonding the base film master to the extruded plastic. The cooled product17 coming off the chilled rolls will not appear to have any embosseddesign present. When the film is removed, the embossed pattern willreveal it self. Such peeling to reveal can be a subsequent step duringin-line production such as of the primary film 16, or this revealing canoccur when an ultimate product is made, such as a sportsboard. In anoptional approach, the peel and reveal could be done by the ultimateconsumer on suitable products.

It will be appreciated that this method leaves an inverse image on theprimary film 16 from the original hologram exposed on the base substratefilm 14. This does open up opportunity to create duplicate holographicimages. In addition, after peeling from the base 14, the embossedprimary film 16 is not protected by another coating and therefore oilsor other substances can fill in the embossed pattern, effectively makingit disappear. However, in most cases a washing with mild soap and waterwill remove the contaminants and restore the product to its originalform before proceeding with subsequent operation, such as dyesublimation printing.

As previously noted, the invention is particularly well suited as anintermediate in the manufacture of various products. The invention iswell suited for incorporation to products intended for rugged use whereholograms traditionally are not suitable for long-term use because themultiple components of a traditional hologram product are susceptible tosplitting apart during hard use. Products made according to theinvention embody holographic or embossed substrates that are devoid ofweak layers. The result is a rugged product having holographic-styleeffects and, if desired, co-existing printed art work which does notinterfere with visual aspects of the holographic effects.

Examples of rugged products include recreational sportsboard substrates.Such substrates can be principal components of recreational productssuch as snowboards, wakeboards, boogieboards, kneelboards, snow skis,water skis, skateboards and so forth.

The extruded polymer primary film 16 can itself be a product ofcommerce. For example, such a product would be sold by a filmmanufacturer to a manufacturer of products in need of aholographic-style decorative finishes that have good durability. Thelatter manufacturers could be of bulky devices such as the recreationalsportsboards noted herein, for consumer goods such as housewares, forvehicle accessories, signage, toys and so forth.

A typical intermediate product is exemplified by the sublimation inkedproduct of FIG. 5 and the conventionally printed product of FIG. 5 a,which could be suitable for sale as an intermediate product used inmaking ultimate products of the type discussed herein. An extrudedpolymer primary film 16 a has sublimation dye printing beneath itssurface, thereby achieving the non-obscuring advantage. Jagged etch cuts13 are visible throughout the surface of the product as it is shown inFIG. 6. This includes within printed areas 21 and unprinted areas 22.

FIG. 7 illustrates an intermediate product, generally designated as 20,that is especially well suited for recreational sportsboard use. In thisinstance, the base holographic-style film 14 remains positioned over theextruded polymer primary film 16, thereby obscuring the holographiccharacteristics such as the embossed jagged etch cuts. In addition,backing material suitable for appropriate bonding to sportsboards andthe like is included in the product 20 depicted in FIG. 7. In essence,the backing is a layer of porous non-woven fleece 23 secured to theextruded primary film 16, in this instance through a thickness 24 ofinterlocking fleece and extruded polymer of the primary film 16. Themakeup of a fleece backing is generally known in the art, as is itssuitability for attaching to sportsboards.

Examples now are provided in order to illustrate the concepts of theinvention with a certain degree of specificity.

EXAMPLE 1

Sportsboard substrates (used in the manufacture of snowboards,wakeboards, boogie boards, kneeboards, snow skis, and water skis) areprepared from materials that include PBT, ABS, ultra high molecularweight polyethylene and nylon. These materials are chosen for theirdurability as well as for the ability to be sublimation dye diffusionprinted. These materials then are bound to a non-woven material on thebackside in order to allow bonding sites for fiberglass through a manuallay-up operation. In this Example, the non-woven material used is an 8mil. type, namely DuPont SONTARA® brand non-woven stock.

In one embodiment, an 8 to 9 mil. extruded PBT primary substrate 16 iscapped with an image bearing holographic base film 14, and these areseparated when desired. The holographic film is identified by the “DeepGroove” trade name, 2 mils. thick sold under the trademark Spectratek®of Spectratek Technologies, Inc. This results in providing a holographicimage that resides on the principal surface of the board substrate.During the dye diffusion printing operation, the print sublimates belowthe prismatic surfaces of the holographic image and does not obscure theembossed pattern that had been formed on the PBT substrate. This leavesthe holographic image visible in both the printed and unprinted areas ofthe PBT surface. The substrate having the holographic image thusobtained is suitable for use in high impact, temperature resilientapplications such as snowboards in which conventional holographic imageswould fail because of their frangible nature particularly due to thehigh refraction index (HRI) treatment applied to conventionalholographic images, which the present invention recognizes results in aweak metal interface that can separate from holographic images appliedto substrates that are subject to rugged uses.

EXAMPLE 2

Profile sheets are products that can be sold as intermediates tomanufacturers wishing to add holographic character or decoration toitems they manufacture by having profile sheet products have aholographic film capped on the top of the product to attract attentionto the product or printed piece. These are manufactured either in-linewith an adhesive coated holographic film or off-line through a wet orthermal lamination process. There are shortcomings with this method. Theholographic film ultimately can be removed from the substrate it wasattached to, which is an undesirable feature. Also, the differences inthermal expansion coefficients between the filth and the substrate canresult in some curling of the finished product if this is done through athermal process.

According to this Example, a commercially available holographic film ofthe type described herein (such as a SPECTRATEK® film) is capped to aHIPS sheet and removed. Once the holographic film is removed, thisprimary surface of the HIPS sheet is subjected to a high dischargeelectric corona to increase the surface energy and allow forconventional printing. The product is printed via screen, flexographic,lithographic, and any other ink depositing methods known in theindustry. When dye diffusion thermal printing is not the printing ofchoice, the inks are not transparent and will fill in the embossedpattern. This Example results in the holographic image being visible inonly the unprinted or uncoated areas. This approach is best suited forprinted pieces that will not be excessively handled as contaminants willalso fill in the embossed pattern and obscure the holographic image. Formany such contaminants, this can be restored through washing with mildsoap and water in most cases. Alternatively, the base layer can remainto preclude such contamination, leaving it to the user peel it off toreveal the embossed image.

When the embossing and conventional printing processes are used to makea profile sheet stock for sale as an intermediate or component formanufacturers wishing to add a holographic character or decoration toitems they manufacture, the profile sheet with or without the base layerobscuring the embossing can be sold as this type of intermediate. Also,the HIPS can be replaced by or combined with a different hightemperature resin, as noted elsewhere herein.

It will be understood that the embodiments of the present inventionwhich have been described are illustrative of some of the applicationsof the principles of the present invention. Numerous modifications maybe made by those skilled in the art without departing from the truespirit and scope of the invention, including those combinations offeatures that are individually disclosed or claimed herein.

1. A decorative holographic-style substrate for a product intended forrugged use, comprising: an extruded polymeric primary film substratehaving embossed images with holographic-style prismatic surfacesextruded therein from a master film having holographic-style prismaticimages with a plurality of differing depth characteristics that reflectlight at differing angles, the embossed images with prismatic surfacesare visible on a face of the extruded polymeric primary film and providethree-dimensional decorative characteristics to products to which theextruded primary film is applied; said embossed images with prismaticsurfaces of the extruded primary film substrate are holographic-stylediffractive optical elements of image-imparting prismal etching andjagged etch cuts; said extruded polymeric primary film is comprised of apolymer having a melt temperature of at least about 175° C.; saidextruded polymeric primary film is comprised of a sublimationdye-receptive polymer that accepts dye sublimation printing; and asublimation dye pattern on the embossed images at the face of theextruded polymeric primary film that has the embossed images withprismatic surfaces, and wherein (i) the embossed images and theirprismatic surfaces that are holographic-style diffractive opticalelements of image-imparting prismal etching and jagged etch cuts and(ii) the dye pattern are simultaneously visible at identical locationsof the substrate.
 2. The substrate according to claim 1, wherein thepolymer of the extruded polymeric primary film has a melt temperature ofat least about 200° C.
 3. The substrate according to claim 1, whereinthe polymer of the extruded polymeric primary film is a thermoplasticpolymer selected from the group consisting of a polyester, polybutyleneterephthalate, polytrimethylene terephthalate, acrylics, nylons,polyurethanes, and combinations thereof.
 4. The substrate according toclaim 1, further including a backing applied to the surface of thesubstrate that is opposite to the face of the extruded polymeric primaryfilm that has the embossed images.
 5. The substrate according to claim1, wherein the embossed images with holographic-style prismatic surfacescomprise patterns of variable shifting spectral coloring.
 6. A productintended for rugged use and having a decorative holographic-stylesurface, comprising: a product intended for rugged use and including onan external portion thereof an extruded polymeric primary film substratehaving embossed images with holographic-style prismatic surfacesextruded therein from a master film having holographic-style prismaticimages with a plurality of differing depth characteristics that reflectlight at differing angles, the embossed images with prismatic surfacesare visible on said external portion of the product and providethree-dimensional decorative characteristics to said product; saidembossed images with prismatic surfaces of the extruded primary filmsubstrate are holographic-style diffractive optical elements ofimage-imparting primal etching and jagged etch cuts; said extrudedpolymeric primary film is comprised of a polymer having a melttemperature of at least about 175° C.; said extruded polymeric primaryfilm is comprised of a sublimation dye-receptive polymer that acceptsdye sublimation printing; and a sublimation dye pattern on the embossedimages at the face of the extruded polymeric primary film that has theembossed images with prismatic surfaces, and wherein (i) the embossedimages and their prismatic surfaces that are holographic-stylediffractive optical elements of image-imparting prismal etching andjagged etch cuts and (ii) the dye pattern are simultaneously visible atidentical locations of the substrate.
 7. The product according to claim6, wherein the product is a recreational sportsboard.
 8. The productaccording to claim 6, wherein the polymer of the extruded polymericprimary film is a thermoplastic polymer selected from the groupconsisting of a polyester, polybutylene terephthalate, polytrimethyleneterephthalate, acrylics, nylons, polyurethanes, and combinationsthereof.
 9. The product according to claim 6, further including abacking applied to the surface that is opposite to the face of theextruded polymeric primary film that has the embossed images, saidbacking being between the extruded polymeric primary film and theexternal portion of the product.
 10. The product according to claim 6,wherein the embossed images with holographic-style prismatic surfacescomprise patterns of variable shifting spectral coloring.